HydroCycle Aquaponic Systems ©2021 Growers Supply All Rights Reserved. Reproduction is prohibited without permission. 112667 AQUAPONICS SYSTEM V *Actual system layout may differ from example shown. Revision date: 04.08.21 1 Important Information Contents USING THIS MANUAL The commercial aquaponic system is a large system with many parts. This manual is divided into different sections. Each section shows one Important Information .................................................................................2 procedure or multiple related procedures . For best results, before General Information & Maintenance .........................................................5 assembly begins, read through this entire document to better understand Aquaponic System Site Plan—Sample ........................................................7 the different assembly procedures. Recommended Setbacks for 30' x 96' Building ..........................................8 Overall assembly process depends on available space and assistants. Recommended System Layout for 30' x 96' Building ...............................9 Construction of main components such as raft and media beds can occur Assemble Stands for 250 & 1,200 Gallon Tanks .......................................10 at any time. Since these require the most space during assembly, Drum Filter Stand Assembly .......................................................................15 it may be best to store frame components outside of the assembly Fingerling System: Tank Templates & Install Fittings ..............................16 area and first set tank stands and tanks in place. Fingerling System: Install Drain Plumbing ................................................19 When it is time to assemble raft and media bed frames, separate the Fingerling System: Attach Bead Filter & Pump Assembly .......................21 different frame components. Review the different sections of this manual Grow-Out System: Tank Templates & Install Fittings ..............................22 to identify raft and media bed frame part numbers. Doing this helps Grow-Out System: Install Drain Plumbing & Standpipes .......................26 prevent confusion and mistakes during assembly. Grow-Out System: Drum Filter Plumbing.................................................28 Grow-Out System: Tank Plumbing .............................................................29 Use the recommended layout diagrams on the following pages to get started. If you are constructing a greenhouse or other building to house Grow-Out System: Drum Filter ...................................................................30 the aquaponic system, ensure there is a sufficient opening for the 1,200 Construction of Media & Raft Beds ............................................................31 gallon tanks and stands to pass through. Fingerling System: Media Bed Diagrams ...................................................32 Grow-Out System: Raft Bed Diagrams .......................................................46 Here are steps to prepare for assembly and to help get you started: Water Temperature: Heating Raft Beds ......................................................54 1. Read through this manual to better understand the different assembly Install 4" Bulkhead & Adapter .....................................................................59 procedures. Review Table of Contents (left column). Install 2" Bulkhead & Adapter for Pump Station ......................................60 2. Determine basic system layout and placement in building. Install 4" Raft Bed Connecting Tubes & Supports ...................................61 Supply Plumbing & Pump Stations .............................................................63 3. Locate all bed liners and move to a safe location until installation. Grow-Out System: Raft Bed Pump & Supply & Drain .............................64 4. Set stands and tanks (without stands) in place. Fingerling System: Pump Station & Supply & 4" Drain Lines .................68 5. Take inventory of all plumbing parts and PVC tubing. Fingerling System: Standpipes & Gravel Guards .......................................76 Outlet Pipe: Grow-Out System Sump .........................................................80 6. Separate and inventory the different media bed and raft bed parts. Aeration System: Fingerling & Grow-Out Systems ..................................81 7. Begin assembly. Prepare Plant Rafts ........................................................................................88 Install Shade Cloth & Bird Netting .............................................................89 CAUTION: Tanks are heavy when filled. Building floor must be capable of supporting all tanks when filled. Finished concrete is System Start-Up .............................................................................................90 recommended to prevent settling. Take the necessary steps to Adjust Flow Rates ..........................................................................................91 construct a solid surface before setting tanks. Once filled, tanks Fish Stocking ..................................................................................................95 cannot be moved. 2 112667 Revision date: 04.08.21 Important Information READ THIS DOCUMENT BEFORE YOU BEGIN Thank you for purchasing the 112667 Commercial Aquaponic System. When properly assembled and maintained, this system will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the system. Please read and understand these instructions before you begin. If you have any questions during the assembly, contact customer service. SAFETY PRECAUTIONS ASSEMBLY PROCEDURE WARNING: Enlist the services of an experienced electrician when connecting • Wear eye protection. Following instructions as presented will help power to pumps and other electrical ensure proper assembly of your aquaponic • Wear gloves when handling metal pipes. components. system. Steps outlining assembly are as follows: • Use a portable GFCI (Ground Fault Circuit 1. Verify that all parts are included in the All wiring to be completed according to Interrupter) when working with power tools and shipment. Notify customer service for established codes and practices. cords. questions or concerns. See below. DROWNING HAZARD: Never allow REQUIRED TOOLS 2. Read and understand these instructions and children or others within the boundary of The following list identifies the main tools needed to the information included with the shipment the tanks, raft beds, and pump stations at assemble the aquaponic system. Additional tools before you begin. any time. may be needed. 3. Gather tools and recruit assistants. Always have an assistant present during • Tape measure and marker 4. Assemble aquaponic system. harvest, tank cleaning, and system maintenance to prevent accidents. • Clutched drill driver (cordless with extra 5. Read additional information as presented. batteries works best) ABOUT THIS MANUAL • Small hammer and gloves UNPACK AND IDENTIFY PARTS This manual describes how to set up your • Level (4' or longer) and line level The following steps will ensure that you have all aquaponic system and check for proper the necessary parts before you begin assembly. operation. Additional information is presented • Utility knife or scissors; tool to cut PVC tubing regarding basic system maintenance. 1. Unpack contents of shipment and place where • Assorted hand tools common to construction, you can easily inventory parts. Refer to Bill of plumbing, and electrical work This manual does not however describe Materials/Spec Sheets. how to grow various types of fish and plants. • Drill bit set with assorted bits. 2. Verify that all parts listed on Bill of Materials/ Since the specifics of such an undertaking Spec Sheets are present. If anything is have filled many books, it is best to • Hole saw bits: 2-1/4", 2-1/2", 3", and 5" missing or you have questions, consult all determine beforehand exactly how you want • Small hand-held grinder with metal cutting bit to diagrams and photos for clarification, or to use this system. Water quality, location, cut expanded metal. contact Customer Service. growing environment, available resources, personal knowledge and experience among • Large adjustable pliers (3"-4" jaw) or strap NOTE: At this time, you do not need to open other things all must be considered before wrench to tighten large bulkhead fittings. the plastic bags containing smaller parts populating system with plants and fish. • 3/16" & 7/32" hex (Allen) wrench or bits — such as fasteners or washers (if equipped). preferably bits to attach to power drivers. Used Consult with your sales representative for to install 112772 & 115303 screws. FLOOR DRAIN: The drum filter included with additional resources and information to ensure a successful start. this system requires a floor drain to accept water during the high pressure rinse cycle. Revision date: 04.08.21 112667 3 Important Information A NOTE ABOUT COLOR CODES REGARDING COMPONENTS IN THIS KIT COLOR CODE Many parts are marked with a specific color to help with identification, inventory, and assembly. When possible, ATTENTION: When noted, a separate shipment by color before you begin. In the event that a part is not found, it is possible it is packaged color code is found in upper- with another color as many parts, especially PVC pipe and fittings, are the same and used in different sections of right corner of a page. the aquaponic system. Review color codes presented below and take note of their use throughout this assembly guide. If bags get opened and parts are mixed during assembly, use actual part ID number and diagrams presented throughout this guide for additional guidance. Colors not shown in diagram: BLACK – Aeration components BLUE for Fingerling and Grow-Out Fingerling System & Related Systems. Plumbing RED – Miscellaneous & large PURPLE components used throughout Bead Filter & Related Plumbing for system. Fingerling System GREEN Media Bed Frame & Liner for Fingerling System YELLOW Grow-Out System & Related Plumbing ORANGE Drum Filter Stand for Grow-Out System WHITE Raft Bed Frames & Liners for Grow-Out System ATTENTION: Actual tank stands may differ from those shown throughout this manual. 4 112667 Revision date: 04.08.21 General Information & Maintenance SITE BEAD FILTER The linear layout throughout this guide shows the aquaculture system Regular maintenance of the bead filter ensures efficient and dependable running parallel with the hydroponic system. This layout allows for even operation. Review and follow these procedures to maintain the bead filter: flow of water throughout both systems. Any layout that varies from this suggested model may require gate valve adjustments and additional • During setup, plumb the purchase of PVC pipe and fittings. discharge end of the three- way valve directly to a drain, or Routine maintenance of the aquaculture system requires flushing valves elsewhere for offline processing and lines. If possible, position drain line outlets near (or pipe directly into) a of solids. floor drain. Clean solids off floor to prevent pathogen growth. • Backwash bead filter at least every other day. This process If entire system is located in a greenhouse, installing 100% shade material requires draining all water from above the aquaculture section is strongly recommended. Shade helps the filter to eliminate solid waste prevent algae issues in tanks (fish tanks, biofilter tank, and sump tank). that collects. FLOW RATES IN TANKS • For a more robust backwash, a pump can be plumbed to the Flow rates are measured by timing how long it takes to fill a known volume bead filter discharge to extract of water: (e.g., 5 gallon bucket = 5.63 gallons). Adjust rates using the ball solids. valves at each tank. See the "Adjust Flow Rate" section near the back of • Maximum operating pressure is this manual. 10 psi. Use the inline ball valve and pressure gage preceding DRUM FILTER the bead filter to adjust and manage pressure. Drum filter requires routine maintenance as described in documentation included with filter. Proper record keeping of this maintenance is strongly • Read, understand, and follow all directions found in the documentation recommended to ensure uninterrupted operation. Read and understand the included with bead filter. filter documentation before system startup and to troubleshoot system after 1,200 GALLON AND 250 GALLON TANK STAND DESIGNS startup. This system includes redesigned tank stands for the 1,200 and 250 gallon tanks that are stronger and easier to level. These new designs require minor assembly before setting tanks and installing plumbing. Size and weight of each stand for a 1,200 gallon tank require the assembly of these stands in the area where the system will operate. Stands are not easily moved once assembled. Additionally, many diagrams throughout this assembly guide show the original tank stands for both the 1,200 and 250 gallon tanks. Stands IMPORTANT: WINDOW KITS FOR FISH TANKS function the same regardless of the design difference shown in some diagrams and photos. When setting tank stands, orient stand so If window kits were purchased for the 250 or 1,200 gallon fish tanks, install support legs allow easy installation and routing of plumbing as those before preparing tanks and setting them in place on tank stands. shown in diagrams. and photos. Revision date: 04.08.21 112667 5 General Information & Maintenance FINGERLING SYSTEM: RAPID DRAIN-TO-WASTE VALVES GROW-OUT SYSTEM A ball valve at the end of each drainage line is designed to rapidly drain water from the fish tanks. To prevent biofouling, flush these valves once a day. (See 1 & 2 below.) GROW-OUT SYSTEM: RAPID DRAIN-TO-WASTE 1200 Gallon The 2” plumbing at the bottom of the external standpipes in the grow-out system are designed for rapid discharge of tank water. To prevent accumulation of heterotrophic bacteria (biofouling) in pipes, open and close these valves once a day when in production. (See diagram at right.) NOTE: The only way to empty a grow-out tank is to open these 2" valves. 2" External Standpipe FINGERLING SYSTEM 50 Gallon 140 Gallon 250 Gallon 2 250 Gallon 1200 Ball valve installed 1 Gallon near end of each 2" drain tube for rapid drainage of tanks. 1 2 6 112667 Revision date: 04.08.21 Aquaponic System Site Plan—Sample 1 Diagram below shows the basic layout of the 112667 aquaponic system. Use this diagram when planning where to position your system. Review all diagrams and photos in this guide before you begin. ATTENTION: Diagram below shows recommended system layout. Increasing distance between tanks or between tanks and beds may require the purchase of additional PVC tubing, or fittings, or both. Top View ATTENTION: Actual tank stands may differ from those shown throughout this manual. Revision date: 04.08.21 112667 7 Recommended Setbacks for 30' x 96' Building 1 Diagram below shows recommended setbacks from building walls. Needs specific to your operation may require a different layout with alternative setbacks. Quantity of pipe and fittings included with this system is based on recommendations found throughout this guide. Altering dimensions shown may require the purchase of additional PVC and related fittings. ID# FINGERLING SYSTEM COMPONENTS ID# GROW-OUT SYSTEM COMPONENTS a 250 GALLON TANK (AQ103); STANDS: See 1a to assemble. A 1,200 GALLON TANK (AQ100); STANDS: See 1b to assemble. b 50 GALLON TANK (AQ104); STAND (AQ105) B MICRO-SCREEN DRUM FILTER (117166) & STAND c 140 GALLON TANK (AQ102) – SQUARE C 410 GALLON BIOFILTRATION TANK (AQ101) d SYSTEM PUMP (111148) D 140 GALLON SUMP TANK (AQ102) e BUBBLE WASH BEAD FILTER (AQ110) Fingerling system is shown with 250 gallon tanks set near outer wall so plumbing can be attached to outer wall of building. Adjust tank layout if a 2.5' setback is desired. 66" Fingerling System — d e 16' (inside) Begin with Section 2. b a a 51" c 32' Media Bed (inside) Outside 2' 96" A 66" 103" 48'-4" Raft Bed (inside) Outside C 30' B 48'-10" Raft Bed (outside) D 48'-4" Raft Bed (inside) a e r A A A k r o W Maximum 2.5' Grow-Out System — Begin with Section 3. 96' 88 112667 Revision date: 04.08.21 Recommended System Layout for 30' x 96' Building 1 Diagram below shows recommended distances between system components. Needs specific to your operation may require a different layout. Quantity of pipe and fittings included with this system is based on recommendations found throughout this guide. Altering dimensions shown may require the purchase of additional PVC and related fittings. Slight adjustments can be made to accommodate personal preferences. 12" 50 Gallon 250 250 Gallon Gallon 140 Gallon Media Bed Minumum 2.5' Maximum 3' Allow just enough 1,200 1,200 space for maintenance. Gallon Gallon Does not need a walkway. Raft Bed Raft Bed 410 Gallon Maximum 3' 140 Raft Bed Gallon 1,200 1,200 Gallon Gallon 10' On-Center Revision date: 04.08.21 112667 9 Assemble Stands for 250 & 1,200 Gallon Tanks 1a ASSEMBLE TANK STANDS — General Information This commercial aquaponic system includes two (2) separate systems: the grow-out system and fingerling system. (See setback and layout diagrams on previous pages.) Each system functions independently and can be assembled as such. To best judge positions of media and raft beds and to ensure economic use of available space and PVC pipe, assemble and set all stands in place to get started. Section 1a: Review diagrams on previous pages, assemble and set main tank stands according to layout dimensions shown. Review overall layout and position stands so system plumbing can be connected as shown in diagrams. Turn stands so support legs do not interfere with plumbing installation. Gather the components shown at the right and stage for assembly. Assistants are required to move and level the assembled stand. Do not move alone! ATTENTION: The stands for the 250 and 1,200 gallon tanks are heavy when assembled. These should be assembled at or near the spot where they will be in use to minimize moving and to facilitate leveling of each stand. Once assembled and leveled, they cannot be moved without repeating the leveling steps. Leg support assemblies require a solid surface. If stands are not positioned on concrete as recommended, take additional steps to construct a solid base on which to mount each tank stand support. Take the necessary steps to firmly pack the soil or gravel and then bury concrete blocks, pavers, or solid wood blocks level with finished grade for each support. Do not set on soil, sand, or gravel. Do not set tank stands on raised blocks or platforms. IMPORTANT: To ensure proper water levels throughout the system during operation, set tank stands on the same finished grade as the float beds. Review layout diagrams for additional details. Stand for 250 Gallon Tank Stand for 1,200 Gallon Tank ATTENTION: Stands require a solid base such as reinforced concrete or concrete pavers capable of supporting full tanks for adequate support and to prevent settling. Take the necessary steps to construct a solid surface before setting tanks. Review notes above for additional comments. 1100 112667 Revision date: 04.08.21